Induction coil foe ignition systems



BEST AvAsLABLE com April 1927. i 1,623,426

M. MALLORY INDUCTION COIL FOR IGNITION SYSTEMS Filed Oct. 5, 1925 2 Sheets-Sheet 1 nmulllillnmni 50 III www

BEST AVAILABLE COP\ i 1927a Apri 5 M. MALLORY INDUCTION COIL FOR IGNITION SYSTEMS Filed Oct. 5, 1925 2 Sheets-Shea?l 2 gmc/nto@ Mahn Jl/Zaoby atto: w14

Patented Apr. 5, 1927.

UNITED STATES BEST AVAILABLE com MARION MALLORY, OF TOLEDO, OHIO.

INDUCTION COIL FOR IGNITION SYSTEMS.

i Application led October 5, 192

My invention has foryits object to provide an induction coil for ignition systems, particularly, of automobile engines that have parts that may be easily and cheaply constructed and assembled, whereby the coil may be made in quantities by unskilled labor and yet` the coil will have the required eiciency. thatjcan, ordinarilyonly be produced bycareful machining and forming of partsand by exact placement thereof in assembling. The -invention thus relates to a complete unitary structure comprising the core, the coil .and a. resistance elementall of :which coact each with the other parts of theeoil. 4-Also bindingY postsare lprovided and .secured tothe induction coil lforreadily establishing connections lwith external circuits and devices that form the automo- -bile ignition system.v

Constructions containing i the invention may be' varied .in form-or in; theirv details. To illustrate-a-practical application of the invention I have selectedvan linduction coil having core members that aresoformed that they will secure andsupport the parts that form the unitary structure in definite positions relative to each-other. The structure selected as `an example is shown in the accompanyin drawings. y l.

Figure 1 o the drawings illustrates aside view of the induction coil, a part being shown broken away to illustrate adetail ot the construction. Fig. 2 is a view o-a vertical section taken on the plane of the line 2-2 indicated in Fig. l. Fig. 3 is a top view of the induction coil. Fig. 4 is a broken view showing the means whereby parts of the induction coil are locked in position. .Fig 5 -is a broken view showing a means for readily locating and securing the members that enclose the coil. Fig. 6 is a broken perspective view showing parts of the induction coil locked in position. Fig. 7 illustrates a perspective view of one of the caps that cooperate with the other parts of the induction coil to enclose the coil. Fig. 8 is a diagram of an ignition system in which the induction coil may be connected.

The particular induction coil selected for 5o the purpose of setting forth a specific construction containing my invention is one that has a pair of air gaps in its magnet-ic circuit. Its magnetic circuitis completed through two parts that may be formed of magnetic material such as soft laminated iron. One of the partsv forms a core that Serial No. 0,513.

may be termed an Icore and the otherpart a U-shaped magnetic member, the ends of the armsof the U-shaped magnetic member being located so that they extend over Athe ends ot' the core o't' the induction coil and so as to form an air gap in the magnetic circuit through the iron. Thus the I-core is located between lthe ends of the U-shaped magnetic members. It desired a second coil may be located'on the vU-shaped magnetic member inductive etlect .in-the induction coil. In the form of the construction shown the U- magnetic member 1 forms themain supporting :part or frame of the'construction and also the means for maintaining the parts in their relation to eachother.' The U-shaped member has arms 2 that are substantially .square in cross section and the coil 3, which comprises the primary coil 4, the secondary coil 5, andthe laminated iron core 6, 1s secured between the ends of the arms 2 of the U-member l as best shown in Fig-2.

In order that the coil may be protected from water and electrically vinsulated it is contained within a. shell 7 which is closed by means of the caps 8 and 9. The shell and the caps are formed of insulating material.

The caps 8 are provided with recesses 10 which fit the ends of the coil, preferably, so as to receive the ends of the primary coil 4 and thus sustain the coil in position within the shell 7. rIhe recesses l0 are made of suiiicient depth s o as to place the ends of the Icore 6, which are also located in the recesses= in proximity to the ends of the arms 2 of the U-mcmber 1 and thus form, magnetically speaking, a gap in the magnetic circuit between the I-core and the U-member l. The spaces between the I-core and the U-member having substantially the same effect inductively as though t-he ends of the magnetic parts were separated by air gaps. The caps 8 and 9 are also provided with channels 1l that are located in the peripheral portions of the caps as best shown-in Fig. 7. The channels ll have a depth and dimensions for receiving the end edge portions ot the cylinder 7 and thus form a means for sealing the interior of the shell and preventing admission of moisture and dust within the shell. The coil 3' isv thus maintained within a sealed enclosure which protects it from the atmosphere and from the dust of the road.

The wires romthe coils 4 and 5 probetween the arms to produce desired trude through the top and the bottom ot the enclosure, that is, through the caps 8 and. 9 and the secondary coil has a terminal that is connected to the distributor' arm of the ignition system. A binding post is located on the shell 7 for ready connection of the secondary coil 5 With the external circuit and in order to locate the binding post in position Where connection may be readily made, that is, in position Where the binding post may be readily accessible and its parts read-ily operated, the -caps 8 and- 9 and the shell 7 have registeringY parts or members so that in the assembling the shell and the caps may be readily located in a predetermined posit-ion relative to each other. In the construction shown the capsare each provided with portions 12 that protrude from the bottoms of the channels 11 or from cross ridges WithinI thel narrow channels 11. The protruding portions 12, however` do not extend to theV outer edges of the channels whereby the edges or the shell-uint@7 be placed Within the channels and guided thereby when rotated relative to the caps. The edges oli the shell' are. providedwith notches 13 thattit around the protrudingportions-12 so that when the edge portions of the shell are placed Within the channels and rotated the notches will quickly register with the raised portions endl the edges'of the cylinder will step into the bottomsfof the channels. Each of the caps is provided With a hole 15. The primary coil 4 is of coarse Wire and when the caps are placed on the ends of the coil?, the wires are inserted through the holes 15. In making up the coil 3 the end' portionsof the Wire that form the primary coil are located on the same side of the' co-il. rEhi'sis also preferably true of the terminals ot the secondary coil. The bindingpost-s of the induction coil are located on one side ot the shell 7 and at certain points on the caps 8 and 9. Thus'by means ot the registering parts 12 and 13 and the holes 15. the parts of the induction coil may be'detinitely located withk respect to each other with absolute certainty and yet with a readiness that greatlycheapens the cost ot production and all that is required is to make the bends in the Wires to con-nectthem with the binding posts.

O ne binding post is supported on the bracket 16 that issecured to the cap 9. The end of the primary coilis bent over and secured to a binding post 17 that may be formed by means of the scr-en' bolt 1-8 and the nuts 19. The' bracket 16 may be secured by means of hollow rivets 20 that may be cast or formed in the insulating material of which the cap 9 is formed` The other end of the primary coil may be bent about the binding post 21 that is secured in the cap S. The end of the secondary coil may also be passed through the opening 15 in the cap 8 and secured to the binding post 2l which joins. the two coils together at this point. The other end ot the secondary coil may bc connected to the binding post 23 that is 'secured to the sleeve 7 reiierablv at inid- )oint and in the front; o the induction coil for convenience of location. T he connection is made, preferably, Within the sleeve 7 and the distributor arm of the ignition system is connectedA to the binding post 23 by moans of the thumb nut 24 which may be formed ot insulating material when the induction coil is to be installed.

lVhen the caps have been placed in position on the cylinders the U-shaped magnetic member 1 which tits the upper surfaces oft' the caps is forced into position so as to place the arms 2 across the outside surfaces of the caps and thus the parts are securedl in posi:

tion. In order to locate the sleeve and the caps and the parts that they contain or which are supported thereby in agdefinite relation with respect to the U-sh'aped member 1 the caps are provided with recesses ilor receiving the arms 2. Preferably, arallel ridges 27 are formed'- on the outer sur aces ot the caps and are spaced apart so'a-s-to lit the sides of the arms 2 and tl'ius'the arms 2 may be slid between the ridgesA 27 AtoA guide them to a definite position or relation, with respect to the capsl and consequently with respect to the binding postsand the' other parts ofthe induction coil. In order to limit the crosswise movement of the arms with respect to the caps and so as to definitely locate them, with respect to the ends of thc Ilcore 6 of the coil, ridges 2 8 are located on the caps S and 9. The ridges 28 extend across and; are 'spaced'v jfrom the ends of the ridges 27. In orderito locate the parts in their relation, brackets 29- may be' securedx to the ends of the arms 2 by means of bolli-'nv rivets25 andthe bolt. 2 tj1and tit into recesses or otherwise engage with the capsiS and' 9. In the form of construction shown a set' oi' ridges 30 extend' parallel to the ridges 28 and to the ends'o' the ridges 27 and the brackets are so formed and h ave dimensions such that when they are secu-red'to the endsl of the arms 2 portions thereof will lie \\'th' in the space formed between the ridges and, preferably, press against the upper surfaces of the caps and thus will lock the parts in their relation to each other. The brackets are,l preferably, angular in form and before assembly have portions that extend at an angle to each other that is greater than 90 degrees so that when they are' secured to the ends of the arms 2 the portions that make contact with the ends of the arms 2 will be drawn down and the brackets which may be formed of sheet metal having elasticity causes the caps to be elastically pressed against the ends of the shell and thus the container that is formed by the shell and 'ing that time. As is Well known a starting motor requires a large current and the induction coil does not receive the current that it receives when the automobile engine is running and consequently in order to give the ignition coil sutticientcurrent when starting the resistance of the primary coil is madesuiiiciently loW and to prevent the consumption of current during the operation of the engine a resistance is connected in series with the primary coil. In starting the resistance is short circuited which allows a sufficient current to pass through the primary coil to Obtain effective ignition. In the assembly of the induction coil embodying my invention the resistance Wire 3l is Wound upon a horse shoe shaped insulating bar 32 preferably formed of mica and the bar is readily supported in position by means of the binding post 21 and a second binding post 33 that is located on the opposite side of the arm 2 and on the cap 8 of the induction coil. The mica horse shoe shaped bar 32 is placed over the ends of the binding posts 21 and 33 and is secured in position by suitable nuts 34.

A third coil 57 may be located upon the U-shape'd magnetic member l and connected in parallel With the primary coil 4 in order to produce the desired inductive effect on the secondary coil 5. The coil 51 is connected to the binding post 18 at one end and to the binding post 38 at the other end. The binding post 38 is insulatingly supported on the U-shaped magnetic member l which constitutes a core for the coil 5l. The binding post 38 may be insulated by means of the Washers 39 and an insulating sleeve 40. This locates the binding post 38 in a convenient position for making connection with the binding post 2l to which one of the terminals of the primary coil 4 is connected. It desired a spring 42 may be secured to the binding post 38 so that when the U-shaped magnet-ic member l is slid into position the spring 42 Will make contact with the binding post 2l. Preferably, the bolt that forms the binding post 38 will pass through a sheet metal part 43 from which the spring contact 42 extends and the spring 42 will thus be held secured in position and at the same time connection Will be established with the binding post.

Suitable mounting brackets 46 and 47 may be secured by the bolts 26 and 48 to the lower arm 2. The brackets 46 und 4T may be varied in shape according lo the parl. of the car to which the induction coil is supported, in order to preferably support the induction coil so that the core will be located in a vertical position.

The connections with the exteriml circuit may be varied according to the ignition system in connection with which the induction coil is used. Inv the diagram oi' Fig. 8 the resistance Wire 31 is short circuited by means of the switch 50 and the connection is made to the terminals et the resistance wire and from the resistance Wire 3l to the battery 59. One end of each primary and secondary coil is connected to the end of the resistance Wire and the remaining end of the primary coil is connected to the circuit breaker 52 while the remaining end of the secondary coil is connected to the arm 53 of the distributor 54. The contacts of the distributor are connected to the spark plugs 55.

I claim:

l. In an induction coil, a U-shaped mag net-ic member, a shell, a coil located in the shell, a pair of caps for closing the ends of the shell, the caps having channels extending radially With respect to the center of the caps, the arms of the U-member fitting the channels to secure the caps in position on the shell.

2. In an induction coil, a U-shaped magnetic member, a shell, a coil and its core located in the shell, a pair of caps for closing the ends of the shell, the caps having channels extending radially With respect to the center of the caps, the arms of the U-member litting the channels and extending over the ends of the core and for securing the caps in position on the shell.

3. In an induction coil, a U-shaped magnetic member, a shell, a coil and its core located in the shell, the cross sectional areas of the magnetic member and the core substantiall y approximating each other, a pair of caps for closing the ends of the shell, the caps having channels extending radially with respect to the center of the caps, the arms ot the U-member fitting the channels and extending over the ends of the core and for securing the caps in position on the shell.

4. In an induction coil, a U-shaped magnetic member, a shell, a coil located in the shell, a pair of caps for closing the ends of the shell, the caps having recesses extending to the edges of the caps, the arms of the Ul member litting the recesses to secure the caps in position on the shell.

5. In an induction coil, a U-shaped magnetic member, a shell, a coil located in the shell. a pair of caps for closing the ends of the shell, the caps having recesses and locking members secured at the ends of the arms of the U-member and located in the recesses lOO lil

for locking tliecaps in position relative to the shell.

6. In an induction coil, a U-shaped magnetic member, a shell, a coil located in the shell, a pair of caps for closing the ends of the shell, the caps having recesses extending to the edges of the caps, the arms of the U.- shaped member fitting the recesses to secure the caps in position on the shell, the caps having a second set of recesses, locking members secured to the arms of the U-magnetic member and located in the second set of recesses for locking the caps in position on the shell and the arms to the'ca-ps.

T. In an induction coil, a shell, a coil 1ocated in the shell, a pair of caps for closing the ends of the shell, a U-shaped magnetic member for securing the caps in position on the ends of the shell, the arms of the U-member fitting across the top surfaces of the caps, binding posts located on the caps, a horse shoe shaped insulating` member secured to two of the binding posts on opposite sides of one of the arms of the U-shaped member, a resistance wire locatedV on the horse Shoe shaped insulating member.

In testimony Whereo'iI I have hereunto signed my name to this specication.

MARION MALLORY. 

